close controlled manufacturing unit - class d specification

About the Client.

BCM is part of Fareva, one of the world’s leading subcontractors in the industrial and household, cosmetics and pharmaceuticals fields. BCM manufactures consumer pharma and beauty products for many famous brands, as well as special prescription medicines through BCM Specials. It operates from a MHRA and FDA approved factory in Nottingham.

The brief.

In order to upgrade the existing manufacturing facilities in line with the requirements of the MHRA (Medicines and Healthcare products Regulatory Authority), it was decided that each individual manufacturing operation would be enclosed in a controlled environment which would ensure that no cross contamination in either direction could take place. In addition, the creation of dedicated cleanroom environments would allow constant and accurate measurements of the manufacturing operation via a BMS system, and energy performance via an EMS system.

The project title of The Transformation Project is very apt as it will quite literally transform the way in which the current factory operates.

Our solution.

The infrastructure to create the various controlled environments included Kingspan Quadcore Cleanroom Panels and Doors along with Kingspan walk on ceiling panels. New resin screed floors were installed throughout with integrated coved upstands. Flush LED lights were used throughout with PIR control and integrated emergency lighting included. HVAC was a combination of adapting and re-using the existing roof mounted AHU’s for the main production lines, along with dedicated bespoke AHU’s for the dedicated manufacturing vessel enclosures and the associated manufacturing raw materials feed rooms. Sprinkler systems and fire detection facilities were upgraded to suit the new proposals and to ensure full legal compliance.

The project included the design and build of a new dispensary facility which incorporated a controlled drugs security storage unit. The whole project was designed as a rolling programme which would allow production to continue with minimum disruption. This proved to be a challenging target to achieve but with cooperation and planning, the necessary installation works were ‘dove tailed in’ within the production schedules.

The whole project was carried out as a turnkey project by Roshal and was fully completed, commissioned and handed over within budget and on time.

CLIENT FEEDBACK.

Phil Bellamy, Engineering Manager, BCM Fareva, “We chose to award this contract to Roshal as they were an established turnkey contractor with a track record for reliability and professionalism. In this regard we were not disappointed. Their attention to detail and quality of work was superb and their project management team liaised fully with our production management to ensure the minimum of disruption. Their Health and Safety management was second to none and we have no doubt at all that in choosing Roshal, BCM Fareva made the right choice.”